U.S. patent application number 10/866147 was filed with the patent office on 2005-06-30 for method and apparatus for packaging horticultural products.
Invention is credited to O'Connor, Jeremiah.
Application Number | 20050138861 10/866147 |
Document ID | / |
Family ID | 46123783 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050138861 |
Kind Code |
A1 |
O'Connor, Jeremiah |
June 30, 2005 |
Method and apparatus for packaging horticultural products
Abstract
In a method and apparatus for packaging a horticultural product,
especially cut flowers, for transportation, one or more stems are
inserted through a flexible foam block formed from a low density,
low compression force material disposed in an opening of container
such that the foam is compressed. The compression of the foam forms
a water-tight seal around each stem to prevent water or other
liquid inside the container from leaking during shipment of the
horticultural product and insulates each stem from each other
stem.
Inventors: |
O'Connor, Jeremiah;
(Waltham, MA) |
Correspondence
Address: |
PIPER RUDNICK LLP
Supervisor, Patent Prosecution Services
1200 Nineteenth Street, N.W.
Washington
DC
20036-2412
US
|
Family ID: |
46123783 |
Appl. No.: |
10/866147 |
Filed: |
June 14, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60533021 |
Dec 27, 2003 |
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Current U.S.
Class: |
47/41.12 |
Current CPC
Class: |
B65D 85/505 20130101;
A47G 7/07 20130101 |
Class at
Publication: |
047/041.12 |
International
Class: |
A47G 007/07 |
Claims
1. A method for packaging a horticultural product comprising the
steps of: inserting a stem of the horticultural product into a
passage formed in a foam block, the foam block comprising a foam
and having a density between 0.5 and 10 pounds per cubic foot (PCF)
and a compression force/deflection (CFD) between 0.5 and 10 pounds
per square inch (PSI); at least partially filling a container with
a liquid, the container having an opening; and disposing the foam
block in the opening of the container such that the foam block is
under compression and a bottom of the stem is submerged in the
liquid; wherein the foam block forms a watertight seal between the
opening of the container and the stem, and wherein the stem can
take up the liquid.
2. The method of claim 1, wherein the foam block includes a
plurality of passages formed therein, and wherein a stem is
disposed in each of the passages such that each stem of each
horticultural product is insulated from each other stem.
3. The method of claim 1, wherein the foam block is compressed by
at least 28%.
4. The method of claim 1, wherein the foam block is compressed by
at least 36% and no more than 84%.
5. The method of claim 1, wherein the foam in the foam block is
compressed by at least 33%.
6. The method of claim 1, wherein the foam in the foam block is
compressed by at least 42% and no more than 98.7%.
7. The method of claim 1, wherein the foam block is a rubber-based
foam.
8. The method of claim 7, wherein the rubber-based foam is a vinyl
nitrile foam.
9. The method of claim 1, wherein the foam block is
polyethylene-based foam.
10. The method of claim 1, wherein the foam block is
polyurethane-based foam.
11. The method of claim 1, wherein the foam block has a circular
cross sectional shape.
12. The method of claim 1, wherein the container is flexible and
the foam block is compressed by tightening a band around the foam
block and a portion of the container adjacent to the foam
block.
13. The method of claim 1, wherein the container comprises a
flexible bag.
14. The method of claim 1, wherein the container is rigid and the
opening of the container is smaller than the foam block, and the
foam block is compressed as a result of being disposed in the
opening.
15. The method of claim 14, wherein the container includes a
removable cap in which the opening is located.
16. The method of claim 15, wherein the foam block is placed in the
opening of the removable cap before the removable cap is placed on
the container.
17. The method of claim 1, wherein the liquid comprises water.
18. The method of claim 1, wherein the liquid consists essentially
of water.
19. A packaged horticultural product comprising: a container at
least partially filled with a liquid, the container having an
opening; a foam block disposed in the opening, the foam block
having at least one passage formed therein, the foam block
comprising a foam, the foam block having a density between 0.5 and
10 PCF and a CFD between 0.5 and 10 pounds per square inch (PSI);
at least one horticultural product having a stem, the stem being
disposed in the at least one passage such that an end of the stem
is exposed to the liquid; wherein the foam block foams a watertight
seal between the stem and opening of the container.
20. The product of claim 19, further comprising a plurality of
horticultural products, wherein the foam block includes a plurality
of passages formed therein, and wherein a single stem is disposed
in each of the passages in the foam block such that each stem of
each horticultural product is insulated from each other stem.
21. The product of claim 19, wherein the foam block is compressed
by at least 28%.
22. The product of claim 19, wherein the foam block is compressed
by at least 36% and no more than 84%.
23. The product of claim 19, wherein the foam in the foam block is
compressed by at least 33%.
24. The product of claim 19, wherein the foam in the foam block is
compressed by at least 42% and no more than 98.7%.
25. The product of claim 19, wherein the foam block is a
rubber-based foam.
26. The product of claim 25, wherein the rubber-based foam is a
vinyl nitrile foam.
27. The product of claim 19, wherein the foam block is
polyethylene-based foam.
28. The product of claim 19, wherein the foam block is
polyurethane-based foam.
29. The product of claim 19, wherein the foam block is composed of
a vinyl nitrile material.
30. The product of claim 19, wherein the foam block has a circular
cross sectional shape.
31. The product of claim 19, wherein the container is flexible, and
wherein the product further comprises a tensioned band surrounding
the foam block and a portion of the container adjacent to the foam
block.
32. The product of claim 19, wherein the container comprises a
flexible bag.
33. The product of claim 19, wherein the container is rigid and the
opening of the container is smaller than the foam block, and the
foam block is compressed as a result of being disposed in the
opening.
34. The product of claim 19, wherein the container includes a
removable cap in which the opening is located.
35. The product of claim 19, wherein the liquid comprises
water.
36. The product of claim 19, wherein the liquid consists
essentially of water.
37. A method for preparing a packaged horticultural product
comprising the steps of: inserting a stem of the horticultural
product into a passage formed in a foam block; at least partially
filling a container with a liquid, the container having an opening;
placing the foam block in the opening of the container such that
the foam block is compressed by at least 28% and forms a watertight
seal between the stem and the opening, and such that a bottom of
the stem is exposed to the liquid so that the stem can take up the
liquid.
38. The method of claim 37, wherein the foam block includes a
plurality of passages formed therein, and wherein a stem is
disposed in each of the passages such that each stem of each
horticultural product is insulated from each other stem.
39. The method of claim 37, wherein the foam is compressed by at
least 36% and no more than 84%.
40. The method of claim 37, wherein the foam in the foam block is
compressed by at least 33%.
41. The method of claim 37, wherein the foam in the foam block is
compressed between 42% and 98.7%.
42. The method of claim 37, wherein the foam block is a
rubber-based foam.
43. The method of claim 42, wherein the rubber-based foam is a
vinyl nitrile foam.
44. The method of claim 37, wherein the foam block is
polyethylene-based foam.
45. The method of claim 37, wherein the foam block is
polyurethane-based foam.
46. The method of claim 37, wherein the container is rigid.
47. The method of claim 37, wherein the container is flexible and
wherein the foam block is compressed by a band placed around the
foam block and a portion of the container adjacent the foam
block.
48. A packaged horticultural product comprising: a container at
least partially filled with a liquid, the container having an
opening; a foam block disposed in the opening, the foam block
having at least one passage formed therein, the foam block
comprising a foam, the foam block being compressed by at least 28%;
at least one horticultural product having a stem, the stem being
placed in the at least one passage such that an end of the stem is
exposed to the liquid.
49. The product of claim 48, further comprising a plurality of
horticultural products, wherein the foam block includes a plurality
of passages formed therein, and wherein a single stem is disposed
in each of the passages in the foam block such that each stem of
each horticultural product is insulated from each other stem.
50. The product of claim 48, wherein the foam block is compressed
by at least 36% and not more than 84%.
51. The product of claim 48, wherein the foam is compressed by at
least 56% and not more than 80%.
52. The product of claim 51, wherein the foam in the foam block is
compressed by at least 33%.
53. The product of claim 51, wherein the foam in the foam block is
compressed between 42% and 98.7%.
54. The product of claim 51, wherein the foam block is a
rubber-based foam.
55. The product of claim 51, wherein the rubber-based foam is a
vinyl nitrile foam.
56. The product of claim 51, wherein the foam block is
polyethylene-based foam.
57. The product of claim 51, wherein the foam block is
polyurethane-based foam.
58. The product of claim 51, wherein the container is rigid.
59. The product of claim 51, wherein the container is flexible.
60. The product of claim 48, wherein the liquid has a viscosity
approximately equal to water.
61. The product of claim 48, wherein the liquid consists
essentially of water.
62. A method for packaging a horticultural product comprising the
steps of: at least partially filling a container with a liquid, the
container having an opening, the container including a side wall
having a protrusion formed therein; inserting at least one stem of
a horticultural product into the opening such that an end of the
stem is exposed to the liquid; and forming a water-tight seal
between the at least one stem and the opening such that the liquid
cannot escape from the container regardless of the orientation of
the container; whereby air in the bottle will collect in the
protrusion so that the stem will remain submerged in the liquid
when the container is laid on a side with the protrusion is facing
upwards.
63. The method of claim 62, wherein the water-tight seal is formed
using a foam block compressed between the at least one stem and the
opening.
64. The method of claim 63, wherein the foam block includes a
plurality of passages formed therein, and wherein a stem is
disposed in each of the passages such that each of the stems are
insulated from each of the other stems.
65. The method of claim 63, wherein the foam block is compressed by
at least 28%.
66. The method of claim 63, wherein the foam block is compressed by
at least 36% and no more than 84%.
67. The method of claim 63, wherein the foam in the foam block is
compressed by at least 33%.
68. The method of claim 63, wherein the foam in the foam block is
compressed by at least 42% and no more than 98.7%.
69. The method of claim 63, wherein the foam block is composed of a
material having a density between 0.5 and 10 PCF and a CFD between
0.5 and 10 PSI.
70. The method of claim 63, wherein the container includes a
removable cap in which the opening is located.
71. The method of claim 48, wherein the foam block is placed in the
opening of the removable cap before the removable cap is placed on
the container.
72. The method of claim 49, further comprising the step of applying
a force to at least one wall of the container, the force being
sufficient to deflect the at least one wall such that the volume
inside the container is reduced while the removable cap is being
placed on the container and removing the force from the at least
one wall after the cap has been placed on the container, whereby
back pressure in the container is reduced as a result of the force
applied to the at least one wall.
73. A packaged horticultural product comprising: a container having
an opening, the container including a side wall having a protrusion
formed therein; a volume of liquid disposed in the container; at
least one stem of a horticultural product inserted into the opening
such that an end of the stem is exposed to the liquid; and a
water-tight seal between the at least one stem and the opening such
that the liquid cannot escape from the container regardless of the
orientation of the container; wherein the volume of liquid is such
that air in the bottle will collect in the protrusion so that an
end of the stem not located in the protrusion will remain submerged
in the liquid when the container is laid on a side with the
protrusion oriented upward.
74. The product of claim 73, wherein the water-tight seal comprises
a foam block compressed between the at least one stem and the
opening.
75. The product of claim 74, wherein the foam block includes a
plurality of passages formed therein, and wherein a stem is
disposed in each of the passages such that each of the stems are
insulated from each of the other stems.
76. The product of claim 75, wherein the foam block is compressed
by at least 28%.
77. The product of claim 75, wherein the foam block is compressed
by at least 36% and no more than 84%.
78. The product of claim 75, wherein the foam in the foam block is
compressed at least 33%.
79. The product of claim 75, wherein the foam in the foam block is
compressed between 42% and 98.7%.
80. The product of claim 75, wherein the foam block is composed of
a material having a density of between 0.5 and 10 PCF and a CDF
between 0.5 and 10 PSI.
81. The product of claim 75, wherein the container includes a
removable cap in which the opening is located.
82. A light fixture comprising: an inflatable balloon; a light
socket disposed within the balloon, the socket being adapted to
accept a light bulb; a foam block disposed within a mouth of the
balloon; and a pair of wires connected to the socket, the wires
passing through the foam block to an exterior of the balloon.
83. A package for a horticultural product comprising: a container
capable of being at least partially filled with a liquid, the
container having an opening; and a foam block disposed in the
opening, the foam block having at least one passage formed therein,
the foam block comprising a foam, the foam block having a density
between 0.5 and 10 PCF and a CFD between 0.5 and 10 pounds per
square inch (PSI), the passage being sized to accept at least one
horticultural product having a stem; wherein the foam block foams a
watertight seal between the stem and opening of the container when
the stem is inserted into the passage.
84. A package for a horticultural product comprising: a container
capable of being at least partially filled with a liquid, the
container having an opening; and a foam block disposed in the
opening, the foam block having at least one passage formed therein,
the foam block comprising a foam, the foam block being compressed
by at least 28%, the foam block being sized to accept at least one
horticultural product having a stem.
85. The method of claim 1, wherein the stem extends past a lower
surface of the foam block.
86. The product of claim 19, wherein the stem extends through the
at least one passage and an end of the stem is submerged in the
liquid.
87. The method of claim 37, wherein the stem extends past a lower
surface of the foam block and the bottom of the stem is submerged
in the liquid.
88. The product of claim 48, wherein a bottom of the stem extends
past a lower surface of the foam block and is submerged in the
liquid.
Description
[0001] This application claims priority from U.S. Provisional
Application Ser. No. 60/533021, entitled "Device For Shipment of
Horticultural Products," filed Dec. 27, 2003. The entirety of that
provisional application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to horticultural products,
and more particularly to a method and apparatus for packaging
horticultural products such as cut flowers.
[0004] 2. Discussion of the Background
[0005] The market for horticultural products, particularly cut
flowers, is large and continues to grow. In this industry, it is
important that the horticultural product be fresh when it is
presented to a consumer. The freshness of the horticultural product
will determine both (1) how the product initially appears to the
consumer, and (2) how long the product will last for the consumer.
The product's initial appearance is particularly important in a
retail setting such as a cut flower display in a store because
consumers will often base their purchasing decision on the initial
appearance. However, initial appearance is also important when
pre-paid flowers are delivered to a consumer. How long the flowers
last is also an important part of customer satisfaction--most
customers will not be happy with flowers that wilt the day after
they are received no matter how nice they looked the previous
day.
[0006] The manner in which horticultural products are shipped plays
an important role in both the initial appearance of the
horticultural product and how long the horticultural product will
last. Today, cut flowers are typically shipped from a grower by
airfreight without water. Then they are either repackaged into an
upstanding, open box with 1"-2" of water on the bottom such that
the ends of the stems can take up water to keep the flowers fresh,
or they continue through distribution without water. With either
method, the flowers are typically refrigerated to preserve their
freshness. Both of these methods have obvious drawbacks. Shipping
the flowers dry reduces their life no matter how well they are
refrigerated. Shipping the flowers in an open container partially
filled with water requires that the containers not be overturned
during shipping, which increases shipping costs and distribution
time.
[0007] Some attempts to provide a device that will allow flowers to
be shipped such that their stems are in water have been disclosed
in the patent literature. However, each of these alternative
devices has drawbacks and, to the knowledge of the inventor, none
of the alternative devices has met with any commercial success.
[0008] U.S. Pat. No. 2,453,906 to Hamlet discloses a device
including tubular container with a "stopper" made in whole or in
part from a "resilient material" inserted into each end. The
stopper in the top end of the tubular container includes a bore
sized to give an air-tight fit around a stem. The stopper is of a
size to make it fit hermetically in the top end of the tube. The
bottom end of the tube also has a stopper with a bore formed
therein. The bottom end also includes a flexible diaphragm that
stretches to fill the void created when water is taken up by a
stem.
[0009] This device has several drawbacks. First, the requirement
for the flexible diaphragm increases the packaging cost. Second,
the "resilient material" illustrated in the '906 patent does not
appear to be very resilient. The drawings show very little
deformation of the material in areas where it is fitted into the
tube. Given the issue date of the '906 patent in 1945, it is very
likely that the "resilient material" is rubber. The problem with a
material of such a resiliency is that it requires a relatively
close match between the size of the bore in the stopper and the
diameter of a plant stem inserted therein. Plant stem diameters can
vary from as little as 1/8 inch to as much as 5/8 inch or greater.
Thus, it is necessary to either make the bore to a specific size to
match a particular stem, or provide a plurality of stoppers with
different sized bores to accommodate cut flowers of different
sizes.
[0010] This is not a practical alternative for two reasons. First,
flower stems are not regularly shaped and often have protrusions
(e.g., rose stems have protrusions where thorns are removed). It
would be necessary to size the bore to accept any protrusion or
other irregularity. However, considering the relatively inflexible
material of '906 patent, the walls of bore may not contact the stem
in areas other than the location of the protrusion or irregularity,
resulting in a poor seal. Second, a requirement for matching stem
sizes to bore sizes would be time-consuming, and therefore
expensive, in a mass-production environment. This would be
especially true in an automated mass-production environment in
which thousands of flowers are packaged because stems would need to
be measured, sorted and staged for insertion into pre-arranged
stoppers of the correct size.
[0011] U.S. Pat. No. 5,315,782 describes a device including a
flexible walled pouch filled with a "moisturized gel" of a "fluid
paste consistency" (col. 2, lines 46-66). The top end of the pouch
includes a "puncturable insert" made from a closed cell foam
plastics material such as a "medium density polyethylene foam sold
under the trade name JIFFYCELL." Applicants believe this is a rigid
foam of the type that is commonly green in color and used in floral
arrangements. The edges of the bag are adhered to this foam, and no
compression of the foam is disclosed. The '782 patent teaches
forming a hole for a plant stem in the foam insert by pushing a
sharpened pencil through the foam.
[0012] The most significant drawback associated with the '782
patent is that it does not form a good seal around the stem. The
'782 patent recognizes this when it states that "the tendency to
leak is reduced by that fact that it is a gel material" in the
pouch (col. 3, lines 49-50). If the seal around the stem were good,
then it would not be necessary to use a "gel" rather than water.
The poor seal is caused by the lack of compression and the use of a
rigid foam. Another drawback associated with the '782 device is
that, because the foam is relatively rigid, it is again necessary
to size the hole to the stem that is to be inserted therein.
[0013] U.S. Pat. No. 5,103,586 discloses a device including a rigid
cup-shaped container, a first layer comprised of rigid foam, a
second layer of a "penetrable elastomeric sealing elastomer . . .
chosen to be sufficiently elastic to flow at about room
temperature," and an optional third layer also comprised of a rigid
foam. The sealing elastomer is preferably an RTV silicone rubber
made from a two part liquid silicone that cures into the desired
flowable sealing elastomer. The chief drawbacks associated with
this device are the cost associated with using multiple layers and
the time required for the elastomer to cure.
[0014] U.S. Pat. Nos. 4,941,572 and 5,115,915 to Harris disclose a
device comprising a rigid container with a non-absorbent foam block
that is either preformed of a rigid foam material adhered to the
container or formed from a foamed-in-place foam dispensed from an
aerosol container. Col. 6, lns 43-58. The preformed block
embodiment of this device suffers from the drawbacks of having to
use an adhesive to secure the block to the container and, because
the foam is rigid, the need for sizing holes in the block to match
the stems. The foam-in-place embodiment suffers from the high cost
associated with aerosol foams, and requires something to hold the
stems in place while the foam is introduced.
SUMMARY OF THE INVENTION
[0015] The aforementioned issues are addressed to a great extent by
the present invention, which provides a method and apparatus for
packaging a horticultural product, especially cut flowers, in which
one or more stems are inserted through a flexible foam block formed
from a low density, low CFD (compression force/deflection) material
disposed in an opening of container such that the foam is
compressed. The compression of the foam insulates each stem and
forms a water-tight seal around each stem to prevent water or other
liquid inside the container from leaking during shipment of the
horticultural product.
[0016] In some embodiments of the invention, the foam block is cut
from a solid piece of foam or is molded to a desired shape. In
other embodiments, the foam block is formed by rolling up a strip
of foam that includes a plurality of V-shaped channels formed
therein. In some embodiments of the invention, the container is
rigid. In other embodiments, the container is flexible.
[0017] In one aspect of the invention, the use of compression
provides a significant advantage as compared to prior art devices
in that it allows flower stems to be tightly packed during
shipping. This reduces the amount of space required by an
individual bouquet of flowers. Reducing space during shipping is
very important for large-scale commercial operations in which
multiple bouquets are shipped in a single package.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The aforementioned advantages and features of the present
invention will be more readily understood with reference to the
following detailed description and the accompanying drawings in
which:
[0019] FIG. 1a is a top view of a foam block according to one
embodiment of the invention in an uncompressed state.
[0020] FIG. 1b is a perspective view of the foam block of FIG. 1a
in an embodiment of the invention in which the foam block is
die-cut from a larger piece of foam.
[0021] FIG. 1c is a perspective view of the foam block of FIG. 1a
in an embodiment of the invention in which the foam block is
molded.
[0022] FIGS. 2a and 2b are top views of a non-integral foam block
in rolled (uncompressed) and unrolled positions, respectively,
according to a second embodiment of the invention.
[0023] FIG. 3 is a perspective view of a shipping assembly
employing a foam block and a flexible container (shown prior to
compression of the foam block) according to a third embodiment of
the invention.
[0024] FIG. 4 is a side cross-sectional view of a shipping assembly
employing a foam block and a rigid container according to a fourth
embodiment of the invention.
[0025] FIGS. 5a and 5b are exploded and assembled side cross
sectional views, respectively, of the shipping assembly of FIG.
4.
[0026] FIGS. 6a, 6b and 6c are perspective, side and side views,
respectively, of a container for use in a shipping assembly
according to a fifth embodiment of the invention.
[0027] FIG. 7 is a perspective exploded view of a shipping assembly
incorporating the container of FIGS. 6a-c.
[0028] FIG. 8a is a perspective view of a packaged horticultural
product according to yet another embodiment of the invention.
[0029] FIG. 8b is a side cross-sectional view of portions of the
product of FIG. 8a.
[0030] FIG. 9 is a side cross-sectional view of portions of an
alternative product according to yet another embodiment of the
invention.
[0031] FIGS. 10a-c are perspective view of a packaged horticultural
product according to yet another embodiment of the invention.
[0032] FIGS. 11a-c are top, side cross sectional and perspective
views, respectively, of a device for inserting stems into foam
block according to still another embodiment of the invention.
[0033] FIG. 12 is a side cross sectional view of the device of FIG.
11 in a second position.
[0034] FIGS. 13a-c are top, side cross sectional and perspective
views, respectively, of the device of FIG. 11 in a third
position.
[0035] FIG. 14 is a side view of a portion of a bouquet of cut
flowers arranged in a staggered presentation using the device of
FIG. 11.
[0036] FIG. 15 is a perspective view of a light bulb disposed
within a ballon according to still another embodiment of the
invention.
DETAILED DESCRIPTION
[0037] In the following detailed description, a plurality of
specific details, such as types of foam and amounts of compression,
are set forth in order to provide a thorough understanding of the
present invention. The details discussed in connection with the
preferred embodiments should not be understood to limit the present
invention. Furthermore, for ease of understanding, certain method
steps are delineated as separate steps; however, these steps should
not be construed as necessarily distinct nor order dependent in
their performance.
[0038] The invention is believed to have particular utility for the
packaging of cut flowers for transportation and hence will be
discussed primarily in that context herein. The invention should
not be understood to be so limited and should be understood to be
useful for packaging horticultural products for other purposes
(e.g., display in a retail setting) and should also be understood
to be useful with other horticultural products such as potted
plants as well as other non-horticultural products having regular
or irregular cross sections in the range of typical plant stems as
described herein.
[0039] It has been discovered that the properties of the foam used
in the foam block are very important to achieving a satisfactory
seal around a plant stem. In particular, it has been discovered
that a foam with a combination of low density and low CFD
(compression force/deflection, which is a measure of the
compressability, or softness, of the foam) is particularly well
suited for the invention. Foams with densities between about 0.5
and 10 pounds per cubic foot (according to the ASTM-D-1667 method)
and a CFD between about 0.5 and 10 psi (according to the
ASTM-D-1056 method) are preferred. By way of comparison, a rubber
stopper, which is believed to be the material used in the
above-discussed '906 patent to Hamlet, has a density on the order
of 15-20 pounds per cubic foot and a CFD much higher than 10
psi.
[0040] Within the above-mentioned guidelines, there are several
types of foams that are believed to be suitable for practicing the
invention depending on the expected fluctuation in temperature and
elevation within a given distribution scenario, including:
elastomeric foams (which includes natural rubber-based foams, and
synthetic rubber-based foams including EDPM and nitrile rubber
based foams and blends thereof with vinyl, PVC, and EVA),
polyethylene foams (including cross-linked polyethylene foams), and
polyurethane foams. One foam that has been found to provide a good
seal in the context of the invention is a vinyl nitrile foam sold
under the name SBE-41 Vinyl Nitrile 4, product designation F-06721.
This foam is a nitrile rubber/polyvinyl chloride blend with a
density of 4 lb/ft.sup.3.+-.0.7 lb/ft.sup.3 and a CFD of 3.5
psi.+-.1.5 psi. It carries a 2Cl rating and has been
combustion-modified to meet the standards set forth in UL 94HF-1
and FMVSS-302. Another foam believed to be suitable for use with
the present invention is a cross-linked polyethylene foam sold
under the mark Voltex MM200.
[0041] Because the foam block is used to form a watertight seal,
closed cell foams are used in preferred embodiments of the
invention. However, it is also possible to practice the invention
using an open cell foam provided that the open cell foam is
sufficiently compressed to form a watertight seal (the amount of
compression used with an open cell foam will generally be higher
than with a closed cell foam). An example of an open cell foam
believed to be suitable for use with the present invention is Low
Perm polyurethane foam. Generally, an open cell foam must be
compressed by at least 40% in order for it to act as a closed cell
foam. Thus, when used in the context of the present invention, such
open cell foams must be compressed by 40% plus an additional amount
commensurate with the amounts discussed below, which are relevant
to closed cell foams.
[0042] In some embodiments of the invention, a foam block 100 is
die-cut from a solid piece of foam in the shape shown in FIGS. 1a
and 1b. The foam block 100 preferably includes one or more holes
110 for receiving the stems of cut flowers such as roses. The foam
block 100 of FIG. 1 includes 12 holes (as roses are typically sold
by the dozen) 110, but the number of holes can be more or less as
desired. The holes 110 preferably range from about 1/4" to about
3/8" in diameter. For example, in embodiments of the invention in
which the stem sizes range from 1/8" to 5/8" and the vinyl nitrile
foam discussed above is used for the block 100, the size of the
holes is 3/8" when stems are inserted into the holes 110 without
stretching the holes 110 prior to insertion of the stems. In
embodiments in which fulfillment equipment (discussed in further
detail below) is used to stretch the holes 110 prior to insertion
of the stems, the hole size is 1/4". The foam block 100 also
includes three smaller holes 120 with diameters of {fraction
(3/16)}". The smaller holes 120 are provided to accept greens
(e.g., baby's breath) that accompany the bouquet of cut flowers in
the holes 110. As with the holes 110, the number of smaller holes
120 can vary and, in some embodiments, no smaller holes 120 are
provided. The holes 110 and 120 are typically spaced apart from
other neighboring holes 110, 120 by {fraction (5/32)}" to 1/2",
depending on stem size and the softness of the stems (generally,
the more soft the stem is, the more room between stems is
necessary).
[0043] Referring now back to FIG. 1(b), it can be seen that the
vertical wall 102b of the foam block 100 is concave. This is as a
result of the die cut process by which the foam block 102 is
formed. This shape is advantageous in that it provides a somewhat
more secure mechanical bond when used with a band such as the band
320 described below. It should be understood that the invention is
not so limited and that other embodiments of the invention employ
foam blocks with non-concave surfaces, such as the foam block 190
illustrated in FIG. 1(c) which includes a straight side wall 102c.
The foam block 190 may be formed by molding rather than die-cutting
from a pre-formed piece of foam.
[0044] The foam blocks 100, 190 of FIG. 1 are integrally formed. An
alternative foam block 200 is illustrated in FIGS. 2a and 2b. FIG.
2a is a top view of the block 200 rolled up into a cylindrical
form. In this configuration, the block 200 includes a plurality of
holes 210, each preferably having the same 3/8" diameter as the
holes 100 of FIG. 1a. As shown in FIG. 2b, the block 200 is
comprised of a length of foam having a plurality of channels 211
that terminate in partially circular portions 210'. When the length
of foam is rolled up, the opposite walls of the channels 211 are in
contact with each other leaving no space between them, and the
partially circular portions 210' are closed to form the holes
210.
[0045] The foam blocks 100, 190, 200 illustrated above in FIGS. 1
and 2 each have circular cross sectional shapes. However, the
invention may be practiced with foam blocks of different shapes
(e.g., square, oval, etc.). The foam blocks 100, 190, 200 of FIGS.
1 and 2 preferably have a height H.sub.1 of approximately one to
two inches. However, in other embodiments, the heights of the foam
blocks may be as short as one half of an inch or may be as tall as
is desired, subject to the length of the stems and the container
with which the foam block is used.
[0046] FIG. 3 illustrates a packaged horticultural product 300
according to an embodiment of the invention. The product 300
includes the foam block 100 of FIGS. 1a, 1b, but is should be
understood that either the foam block 190 of FIG. 1c or the foam
block 200 of FIG. 2 could be used in its place. The foam block 100
is disposed in the opening of a container in the form of a flexible
bag 310. The bag 310 of FIG. 3 is plastic, but rubber, latex or any
other suitable material may be used in other-embodiments. A band
320 is used to compress the bag 310 and the foam block 100 (which
is shown prior to compression in FIG. 3) so that a watertight seal
is formed between the foam block 100 and the bag 320, and between
the foam block 100 and stems (not shown in FIG. 3) disposed in the
holes 110, 120 of the foam block 100. The band 320 may be formed of
any suitable material, and comprises a cable tie or nylon strapping
in preferred embodiments of the invention. Such ties typically have
a width of approximately 1/8"-1.5".
[0047] Compressing the foam block 100 (again, shown prior to
compression in FIG. 3) is critical to making the product 300
watertight so that liquid inside the bag 310 does not escape during
shipping regardless of the orientation of the product 300. The foam
block 100 of FIGS. 1a and 1b should be compressed by an amount of
at least 15% when included in the product 300 to ensure that a
watertight seal is formed. Preferably, the amount of compression is
in the range of 20%-60%, and more preferably in the range of
25%-55%. The aforementioned compression values should be understood
to mean that the diameter of a circular foam block with one or more
stems inserted therethrough has been reduced by the amount of the
compression when the compressive force is applied diametrically
around the circumference of the foam block. Thus, for example, if
the diameter of the foam block 100 is 2.25" prior to compression,
compressing the foam block by 20% means that the foam block is
compressed such that its diameter is reduced by 2.25"*0.20=0.45".
The diameter of such a foam block will be 2.25"-0.45"=1.8" when the
block is compressed by 20%.
[0048] The above-stated compression values can also be expressed as
a reduction in cross-sectional area of the foam block in a plane
corresponding to the direction in which the compressive force is
applied. For example, compressing the block such that its diameter
is reduced by 20% will reduce the cross sectional area by
approximately 36%. When expressed in this fashion, the
aforementioned compression ranges correspond to reducing the
cross-sectional area by at least 28%, preferably between 36% and
84%, and more preferably still between 56% and 80%. The foregoing
reductions in cross sectional areas are applicable to circular
blocks as well as non-circular blocks.
[0049] The aforementioned values reduction in cross-sectional area
do not include the effect of stems in the block, which do not
compress. In a typical embodiment, a 2.25" foam block includes a
bouquet of a dozen roses with a stem size of 0.25." The area of
such a foam block is 3.976 square inches (assuming the holes for
the stems are also 0.25"), and the area of the stems is 0.589
square inches. Thus, the area of the foam in the foam block is
3.976-0.589=3.38 square inches. When the area of the block
(including the stems and the foam) is reduced by 28%, its new area
is 2.86." Because the stems do not compress, the area of the foam
in the compressed block is 2.86"-0.589"=2.27." Thus, the foam in
the block has been compressed from an area of 3.38" to 2.27", which
is 2.27/3.38=0.67 or 67% of its original area, a reduction of 33%.
Thus, a 28% reduction in cross sectional area of a 2.25" inch block
that includes a dozen stems with a diameter of a quarter inch
translates to a 33% reduction in cross sectional area of the foam
itself. The corresponding ranges of 36%-84% and 56%-80% translate
to 42%-98.7% and 66%-89%.
[0050] The use of a low density, low CFD foam compressed in the
amounts specified herein provides a water-tight seal without
requiring the use of an adhesive or a sealer around the foam block,
which saves time and money. The use of a low density, low CFD foam
also allows use of the product 300 with plain water disposed within
the bag 310. This is an important improvement over techniques
employed in some conventional applications (e.g., U.S. Pat. No.
2,453,906) that depend upon using a thicker fluid such as a gel
rather than water to hydrate the plant in order to ensure that
leaks do not occur. However, the foregoing should not be understood
to limit the invention to use with water. Rather, it should be
understood that the present invention is not limited to use with
water and may be used with liquids of various viscosities,
including liquids with viscosities approximately equal to that of
water as well as liquids such as gels with higher viscosities. Such
liquids may or may not contain plant nutrients or other
substances.
[0051] FIG. 4 illustrates a packaged horticultural product 400
according to another embodiment of the present invention. The
product 400 includes a plurality of flowers 420, each having a stem
420a inserted into a respective hole 110 of foam block 100. As with
the product 300 discussed above, foam block 190 or foam block 200
may be used in place of the foam block 100. Foam block 100 is
disposed in a container 410, which is preferably made from plastic
and is partially filled with a liquid 425.
[0052] The container 410 is illustrated in greater detail in FIGS.
5a and 5b. The container 410 includes a generally frustoconical
lower portion 411 of height H.sub.1 with a closed bottom 411a and
an open top 411b. A ridge 412 is formed around the open top 411b. A
cap 414 is placed on the open top 411b. The cap 414 includes a lip
415 that mates with the ridge 412 on the lower portion 411 such
that a watertight seal is formed when the cap 414 is pressed onto
the lower portion 411. The mechanical bond formed by the ridge 412
and lip 415 must be sufficiently strong such that the cap 414 will
not become separated from the lower portion 411 during
transportation of the product 400.
[0053] The cap 414 includes a funnel shaped portion 416 and a
generally cylindrical portion 417. The cylindrical portion 417
includes a lower lip 419. The lower lip 419 functions to retain the
foam block 100 as illustrated in FIG. 5b. The cylindrical portion
has a diameter D sized such that the foam block is compressed by an
amount in the ranges discussed above. When the foam block is
compressed in this range, a watertight seal is formed between the
foam block and the stems 420a and the interior surface of the wall
of the cylindrical portion 418 such that water or other fluid in
the lower portion 411 of the container 410 will not leak regardless
of the orientation of the product 400.
[0054] In practice, it is preferable to insert the stems 420a into
the foam block 100 first, next place the foam block 100 into the
cylindrical portion 417 of the cap 414, and then place the cap 414
on the lower portion 411. The amount of air that is trapped and
compressed in the lower portion 411 as a result of fitting the
product 400 together in this manner is less than if the foam block
100 and stems 420 were fitted into the cap 414 after it was in
place on the lower portion 411. Keeping back pressure low can be
important when the product is shipped by air in a partially or
wholly de-pressurized cargo hold at high altitudes.
[0055] A container 600 for use in a packaged horticultural product
according to yet another embodiment of the invention is illustrated
in FIGS. 6a and 6b. The container 600, which is again preferably
formed from a flexible material such as plastic, has an open top
620 and a closed bottom 630. A protrusion 610 is formed on one side
of the container 600 such that the diameter D.sub.3 of the
container 600 is wider in the area of the protrusion 610 than the
diameter D.sub.4 of the bottom end 630 of the container 600. The
protrusion adds to the volume of water that the container 600 can
hold. When the container is filled with a liquid to a level 640c
near the top as shown in FIG. 6c, and is then laid on its side as
shown in FIG. 6b, the water level 640b extends at least partially
into the protrusion 610 such that the bottom 630 remains filled
with liquid (provided that something is disposed within the open
top 620 to prevent the liquid from escaping). This ensures that any
stems disposed within the container 600 remain submerged in the
liquid when the container 600 is laid on its side. In contrast, the
liquid level in a container without the protrusion 610 would drop
far lower when placed in its side, which would likely result in one
or more stems being situated above the liquid level rather than
remaining submerged.
[0056] A packaged horticultural product 700 incorporating the
container 600 is illustrated in FIG. 7. The product 700 is
preferably fitted together in the following manner. First, one or
more stems 710 are inserted into corresponding holes 722 in a foam
block 720. The foam block may be of any of the types illustrated in
FIGS. 1a,b,c and FIG. 2.
[0057] When all of the stems 710 have been inserted into the block
720, and any holes 722 in which no stem 710 has been placed have
been plugged, the block 720 is inserted into an opening 732 in cap
730. The opening is sized such that foam block 720 is compressed by
an amount in the ranges discussed above.
[0058] Next, one or more side walls of the container 600 are
depressed inward and, while the one or more side walls are
depressed, the cap 730 is inserted into the open top 620 of
container 600. Depressing the side walls a small amount prior to
insertion of the cap helps to prevent and/or minimize the amount of
back pressure that is created when the cap 730 is pressed into
place over the open top 620. That is, when the force creating the
depressions on the side walls is removed, the side walls return to
their original position and the volume inside the container is
increased, thereby providing additional room for the expansion of
any air compressed as a result of placing the cap 730 on the top
620.
[0059] The cap 730 is securely held in place over the open top 620
by a tear away strip 740 of the type that is commonly used on
consumer beverage containers, especially plastic milk containers.
Ridges 622, 623 formed around the circumference of the open top 620
aid in the formation of a mechanical bond between the top 620 and
the cap 730 and tear away strip 740, respectively. When the
consumer wishes to remove the stems 710 from the product 700, the
tear-away strip 740 is torn away and the cap 730 is then removed
from the top 620. The consumer can then push the foam block 700
upward out of the cap 730 so that the block 720 decompresses. At
that point, the stems 710 can be removed from the foam block
700.
[0060] FIG. 8a illustrates a packaged horticultural product 800
according to yet another embodiment of the invention. The product
800 includes a foam block 810 through which a plurality of flower
stems 801 (shown in phantom in FIG. 8a) have been inserted. The
foam block 810 is held in place by a cap 820, which is attached to
a container 830.
[0061] Referring now to FIG. 8b, the cap 820 includes a threaded
surface 822 that mates with a corresponding threaded surface 832 of
an opening 831 of container 830. The cap holds an insert 840 (into
which the foam block 810, not shown in FIG. 8b, is inserted) in
place in the container opening 831. The insert 840 includes a lip
844 that rests on an upper surface 834 of the opening 831. The
insert, which is preferably formed of a flexible plastic, includes
a plurality of slits 842. The slits 842 allow the portion of the
insert 841 between the lists to flex, which facilitates the
insertion of the foam block 810. A band (not shown in FIG. 8b;
preferably similar to the band 320 discussed above in connection
with FIG. 3) is installed around the portion of the insert 841 in
the area of the slits 842 to compress the foam block. The lip 849
on the insert 841 hold the band in place.
[0062] Although the rigid containers of the embodiments of the
invention illustrated in FIGS. 4-8 include removable caps, other
embodiments of the invention use rigid containers that do not
include any removable cap. In such embodiments, the foam block is
placed directly into an opening of the container. The container may
be a glass vase in such embodiments.
[0063] FIG. 9 illustrates an alternative assembly 990 that includes
a container 930 with a threaded surface 932 that mates with a
corresponding threaded surface 942 of a combination cap/insert 940.
A foam block (not shown in FIG. 9) is inserted into the opening 941
of the insert 940 and held in place with a band (not shown in FIG.
9) as discussed above in connection with FIG. 8b. When the
cap/insert 940 is screwed onto the container 930, the cap/insert
940 and the foam block disposed therein are held in place on the
container 930.
[0064] FIGS. 10a-c illustrates a latex bag (sometimes referred to
as a stuffing balloon) 910 that maybe used in place of the bag 310
of FIG. 3. The bag 910 is comprised of latex that will flex and
stretch. This allows the bag 910 to expand with changes in
atmospheric pressure such as those encountered in an airplane cargo
hold, thereby relieving pressure exerted on the foam block 920 by
air inside the bag 910 under such conditions. More importantly,
however, the use of a flexible bag 910 allows the bag to conform to
any available space in a shipping container. This is very important
in situations in which a plurality of packaged horticultural
products are shipped in a common container as it minimizes the
volume required for the common container, which reduces shipping
costs.
[0065] The mouth 911 of the bag may be pulled open as shown in FIG.
10b by vacuum equipment (or other equipment known in the art) so
that a foam block 920 may be inserted therein. A plurality of stems
940 are inserted into corresponding openings 922 in the foam block
920 prior to insertion of the foam block into the mouth 911 of the
bag 910. After the foam block 920 has been inserted, a band 930
(which may be similar to the band 320 of FIG. 3) placed around the
outside of the mouth 911 is used to compress the foam block 920 as
shown in FIG. 10c.
[0066] In each of the embodiments shown above, stems may be placed
in each of the openings of the foam blocks. Alternatively, one or
more of the openings may be filled by a plug (not shown in the
figures).
[0067] As discussed above, some embodiments of the invention
utilize foam blocks with passages that are stretched apart by
fulfillment equipment prior to the insertion of stems therethrough.
An exemplary fulfillment device 1100 is illustrated in FIG. 11. The
device includes a plurality of upstanding tubes 1110 with positions
that correspond to holes in a foam block (such as the holes 110 of
FIG. 1). Each of the tubes 1110 has a slightly larger diameter than
the corresponding hole of the foam block. Each of the tubes 1110
has a corresponding finger 1120 disposed therein. The device 1100
also includes four stages 1150, 1160, 1170, 1180 that are movable
with respect to each other, except that stages 1150 and 1170 are
always separated by supports 1155.
[0068] The fulfillment device 1100 is used as follows. First, the
stages are manipulated as shown in FIG. 12 such that stages 1160,
1170 and 1180 are contiguous to each other. This results in the
upper edge of tubes 110 being even with a top edge 1151 of stage
1150 and the upper portions 1121 of fingers 1120 extending above
stage 1150. The upper portions 1121 of the fingers are tapered such
that they are narrower than the holes in a foam block (not shown in
FIG. 13) with which the device 1100 is used. At this point, the
foam block is set in place over stage 1150 such that the fingers
1120 are within the corresponding holes. Next, stage 1160 is moved
toward stage 1150 such that the tubes 1110 extend beyond the upper
surface 1151 of stage 1150 as shown in FIG. 13. In this position,
they are inserted into and stretch a corresponding hole of a foam
block. Next, stage 1180 is moved away from stage 1170 as shown in
FIG. 11 such that most or all of the tubes 1110 are empty and can
accept a flower stem. After flower stems have been inserted into
each of the tubes 110, the tubes 1110 are removed from the foam
block. This allows the holes in the foam block to close around the
stems and the foam block is ready for compression.
[0069] Because the fingers 1120 are of differing heights, flower
stems are positioned in the foam block such that they are at
different depths. Thus, the fulfillment device 1100 allows stems of
cut flowers 1410, to be inserted through a foam block 1420 by
varying amounts, which allows a plurality of equal-length cut
flowers 1410 to be staggered in the manner illustrated in FIG. 14.
This is important because staggering the flowers reduces the size
of a packaged horticultural product, which reduces shipping costs.
In the prior art, staggering was accomplished by arranging the
heads of cut flowers in a staggered pattern, and then cutting all
of the stems evenly. This sacrifices the length of some of the
stems, with the result that the individual stems of the flowers in
the bouquet are of unequal length.
[0070] FIG. 15 is a perspective view of the use of a foam block
1210 with an inflatable balloon 1520 to form a decorative light
fixture 1500. The foam block 1510 includes two passages 1511, 1512
through which pass wires 1534, 1535 for a light socket 1530 holding
a light bulb 1532 disposed inside of the balloon 1520. A third
passage 1513 is provided in the foam block 1510 to allow for a
needle (not shown in FIG. 15) to be inserted through the foam block
1510 to inflate the balloon 1520 (a plug is disposed in passage
1513 to prevent air from escaping after a filling operation). A
band 1522 (similar to the band 320 of FIG. 3) is placed around the
mouth of the balloon 1520 to compress the foam block 1510 so that
air in the balloon 1520 does not escape. A plurality of light
fixtures 1500 may be strung together in the manner of party
lanterns.
[0071] Preferably, flowers are placed in the shipping assemblies of
the present invention as soon as possible after they are cut in
order to extend their life as long as possible. In some embodiments
of the invention, the flowers are packaged at the grower's location
and shipped directly to a consumer, preferably via a common carrier
such as UPS or FEDEX. Alternatively, the flowers may be shipped to
a retail location, where they can be displayed and sold while still
in the packaging. This is particularly advantageous for retail
establishments that desire to sell flowers but do not have the
staff to repackage received flowers for retail sale. In such
embodiments, the container (whether rigid or soft) preferably holds
enough water such that the retail establishment does not have to
add water to the container before it is sold to the consumer.
[0072] It should also be understood that the present invention is
not limited to use with water and may be used with liquids of
various viscosities, including liquids with viscosities
approximately equal to that of water as well as liquids such as
gels with higher viscosities. Such liquids may or may not contain
plant nutrients or other substances.
[0073] Obviously, numerous modifications and variations of the
present invention are possible in light of the above teachings. It
is therefore to be understood that within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
* * * * *